Interconnecting food container system

ABSTRACT

A container which includes a base ( 4 ) with an upper end forming a base rim ( 16 ), and a cover ( 2 ) which can lie right-side-up or upside-down on the base. In the cover upside-down position, a cover channel ( 14 ) opens downwardly and closely receives the base rim ( 16 ), and much of the base recess ( 7 ) is left uncovered.

FIELD OF THE INVENTION

The present invention relates to a rigid food container system configuration for foodstuff that preserves and facilitates the displaying of contents. More particularly, the invention relates to a food packaging containment system where a first food container and a second food container are held together by snap-fit.

BACKGROUND OF THE INVENTION

Restaurants and food markets have utilized rigid containers to protect and display both perishable and fragile food items such as sandwiches, salads and bakery items. Rigid plastic food containers are typically manufactured from Polystyrene, Polypropylene, Polyethylene Terephthalate (PET), Polylactide, Polyvinyl Chloride (PVC), or other rigid polymers. They generally comprise either of two-parts—a tray and lid—or they may be a one-piece construction with a hinge that modifies one portion of the container to act as the tray and the other connected portion to act as a lid. Furthermore, they are available in a variety of shapes and cross-sections—circular, rectangular, square, and elliptical, etc.

These traditional roles of plastic packaging are now the minimum expected standards, and the requirements placed on plastic food packaging continue to expand as increasing demands are placed upon it. Presentation, brand presence, consumer desires, added value to enhance commercial competitiveness, differentiation, imagery and psychology have resulted in the design and application of plastic packaging becoming more challenging. Convenience and versatility continue to shape the future of packaging, with consumers gravitating toward packaged convenience items that minimize the impact on their behavior. This has forced packaging manufacturers to include social and environmental considerations into their development process. The growth of fast food restaurants and the competitive response from food markets offering packaged meal product for consumers “on-the-go” is such an indication of this trend. However, there is a growing body of evidence that consuming fast food product while driving presents enormous hazards. Despite regulation that requires at least one hand on the wheel at all times, much of currently available food product and its packaging is not designed with this regulation in mind. It is difficult, if not impossible, for example, for one to safely consume a food product that may need a condiment or other taste-enhancing feature. Additionally, this form of food consuming has gained more attention since the banning in some areas of handheld cell phones—representing a belief that mufti-tasking when driving is hazardous.

Despite these concerns, this trend is unlikely to stop as consumers lifestyles evolve. The fast food industry is growing and the automotive industry continues to provide in-vehicle accessories and interiors to promote eating and drinking. All this presents opportunities to packaging manufacturers and their food processing clients to develop packaging integrated food solutions especially for convenience-oriented consumers while in transport.

There is a need to offer a variety of convenience-enhancing multiple compartmentalized food trays that take into account driver ergonomics, including the encumbrance consuming food while driving places on the driver and passengers, and existing accessories that currently exist in vehicles. This invention provides for a unique approach that achieves this objective.

SUMMARY OF THE INVENTION

In a preferred embodiment of the invention, the food container system comprises a first tray member and at least one smaller tray member, wherein the smaller tray member is formed with a shaped channel into its underside so that the rim of the first tray may be inserted into the shaped channel. The first tray member acts as the primary supporting means for the smaller second tray member so that a complementary combination of food items may be associated more effectively and will further be efficiently handed from one person to another. For example, the first tray member may contain corn chips or vegetables and a smaller second tray may contain a complementary condiment thereby providing enhanced utility to consumers. Ideally, the weight distribution between the first and the at least one smaller tray member is such that when they are integrated together by inserting the rim of the first tray member into the shaped channel of the smaller second tray member, the integrated food container system is able to stand alone and be held up by the base first tray.

In another embodiment of the invention, the food container system comprises a first tray member and a lid member, that when in its typical market display mode, the food container system stands upright with the base of the first tray member supported on, say, a shelf and the mouth of the lid member is attached to the mouth of the tray member in order to protect its contents using a detachable interlocking arrangement. The detachable interlocking arrangement may be a releaseably lockable snap-fit lock mechanism that ensures that the lid member and the tray member are held firmly together as the food container system is transported. Further, the lid member is formed firstly with a raised roof such that when the said lid member is inverted, it acts as a second smaller tray that can be used to hold additional foodstuff, and secondly with a shaped channel into which the rim of the first tray may be inserted. As in with the prior embodiment, the weight distribution between the first and second tray members are such that the integrated food container system is held up by the base tray when placed on a supporting surface, such as a table. Alternatively, the first tray member may be formed so that it can be held by the consumer with one hand, thereby leaving the consumer's other hand to access the food items in both tray members.

This invention is a novel plastic packaging solution that improves significantly on the convenience and therefore marketability of food product.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is an isometric view of an embodiment of the present invention showing the disassembled smaller second tray member and first tray member.

FIG. 2 is a cross-sectional view of the assembled container system in FIG. 1.

FIG. 3 is an isometric view of the container system in FIG. 1 but with the smaller second tray member inverted.

FIG. 4 is an isometric view of the container system in FIG. 3 assembled ready for use by the consumer.

FIG. 4A is a cross-sectional view of the assembled container system in FIG. 4.

FIG. 4B is an exploded fragmentary sectional view of area P-P of the container system in FIG. 4A.

FIG. 5 is an isometric view of another embodiment of the present invention showing the disassembled smaller second tray member and first tray member.

FIG. 6 is an isometric view of the container system in FIG. 5 but with the smaller second tray member inverted.

FIG. 7 is an isometric view of the container system in FIG. 6 assembled and ready for use by the consumer.

FIG. 8 is an elevation side view of another embodiment of the present invention.

FIG. 9 is an isometric view of the container system in FIG. 8 showing the smaller second tray member assembled to the first tray member.

FIG. 10 is an isometric view of the smaller second tray member of the container system in FIG. 8.

FIG. 11 is a fragmentary sectional view of the container system in FIG. 8 taken along the line N-N in FIG. 9.

FIG. 12 is an elevation side view of another embodiment of the present invention.

FIG. 13 is an isometric view of the container system in FIG. 12 showing the smaller second tray member inverted and assembled to the first tray member.

FIG. 14 is an isometric view of the smaller second tray member of the container system in FIG. 12.

FIG. 15 is a fragmentary sectional view of the container system in FIG. 13 taken along the line 0-0.

FIG. 16 is an isometric view of another embodiment of the present invention.

FIG. 17 is an isometric view of the container system in FIG. 16 showing the smaller second tray member inverted and assembled to the first tray member.

FIG. 18 is an elevation view of the container system in FIG. 17.

FIG. 19 is a fragmentary sectional view of the container system in FIG. 18 taken along the line P-P.

FIG. 20 is an elevation side view of one container system of the container systems in FIG. 16 stacked upon another identical container system.

FIG. 21 is an isometric view of another embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are described. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, the embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art.

Referring to the drawings and in particular to FIG. 1, there is shown a rigid polymer construct food container system 1 according to the present invention. The food container system 1 comprises a first tray member 4 and a second smaller tray member 2. The second smaller tray member 2 is designed to also act as a lid member when it is inverted as shown. To achieve an assembled, “ready-for-sale” condition, the smaller second tray member rim 8 of the food container system 1 is configured so that it mates with the first tray member rim 16. Such attachment is achieved by the use of an annular snap-fit lock mechanism wherein the smaller second tray member rim 8 is releaseably lockable to the first tray member rim 16. The second smaller tray member 2 comprises a planar surface 3 that is lower relative to the smaller second tray member rim 8 but above the floor footing 5 thereby forming a cavity 23 in the second smaller tray member 2, and a curvilinear shaped channel 14 that is further configured to be similar to that of the first tray member rim 16. The shaped channel 14 is further defined by inner sidewall 10 and an opposing outer sidewall 12 between which the first tray member rim 16 is inserted. This feature is exemplified in more detail in FIGS. 3 & 4. Turning first, however, to FIG. 2, therein is shown a cross-sectional view of the assembled, “ready-for-sale” container system in FIG. 1. The snap-fit lock mechanism that is used to releaseably lock the smaller second tray member 2 to the first tray member 4 is further exemplified here. Snap-fit locks have in common the principle that a protruding part of one component, e.g., a hook, stud or bead, is deflected briefly during the joining operation and is lodged in a complementary configured depression in the complementary mating component. In this instance, the snap-fit lock mechanism, as shown, is of an annular ring type wherein a continuous circumferential female groove 9 is formed immediately adjacent to the second smaller tray member rim 8 and which that mates with a complementary continuous circumferential male rib 11 formed at the first tray member rim 16. When the smaller second tray member 2 and the first tray member 4 are assembled in this manner with foodstuff within it, the container system 1 is in a “ready-for-sale” condition. It will be appreciated that the annular ring snap-fit approach provides resistance to leakage that would not be offered by discrete or non-annular (e.g. hook, stud) type snap-fit lock mechanisms. The planar surface 3 of the second smaller tray member 2 is elevated above the second smaller tray member rim 8 by distance H. The distance h between the floor 18 of the shaped channel 14 and the plane of the first tray member rim 16 is preferably not greater than the distance H.

Turning now to FIG. 3, therein is shown the embodiment in FIG. 1 but with the second smaller tray member 2 inverted. The second smaller tray member 2 is shown inverted to display tray recess 19 into which other foodstuff may be placed. For illustrative purposes, shown is a polymer film or foil 25 that may be used to optionally retain the foodstuff within its respective tray recess 7 of first tray member 4. In a similar manner, the foodstuff in the second smaller tray member 2 may optionally be retained within its tray recess 19 with a foil (not shown). Turning to FIG. 4, therein is shown the container system in FIG. 3 with the inverted second smaller tray member 2 attached to the first tray member 4 to form an integrated food container system 21. Attachment of the inverted second smaller tray member 2 to the first tray member 4 is achieved by inserting any segment of the first tray member rim 16 into the shaped channel 14 of the inverted second smaller tray member 2 and causing an interference fit between the inner and outer sidewalls 10, 12 of the second smaller tray member 2 and the first tray member rim 16. FIG. 4A shows an elevation side view of the assembled container system in FIG. 4. Turning now to FIG. 4B, therein is shown an enlarged cross-sectional view of the area P-P in FIG. 4A showing the interlocking arrangement between the first tray member rim 16 of the first tray member 4 and the inverted second smaller tray member 2. The inner sidewall 10 and outer sidewall 12 are formed at an angle toward each other so that, together, they enable an interference fit with the first tray member 4 at the tray inner wall 13 and at the first tray member rim 16. Further, as shown, when inserted fully, the shaped channel floor 18 preferably sits on the first tray member rim 16 so that the planes of the mouths of the second tray member 2 and the first tray member 4 approximately coincide. The consumer has then a number of options including placing the base of first tray member 4 into, say, an automobile center consol cup-holder or holding the first tray member 4 with one hand while using their free hand to access the foodstuff in both the first and second tray recesses. For example, sliced carrots may be placed into the first tray member recess 7 and a salad dressing placed into the smaller second tray member recess 19.

Turning now to FIGS. 5, 6 and 7, therein are shown renditions of another embodiment of the present invention. In these renditions, when the second smaller tray member 2 is inverted, the curvilinear configuration of the shaped channel 14 is such that it will mate with the first tray member rim 16 only at the complementary curvilinear extended tray rim segment 28 of the first tray member rim 16 as only here is the radius of the shaped channel 14 similar to that of the curvilinear extended tray rim segment 28. Additionally, the shaped channel inner sidewalls 10, 26 & 20 and opposing outer sidewalls 12, 24 & 22 are formed at an angle toward each other so that, together, they make a mechanical attachment with the first tray member rim 16 when said curvilinear extended tray rim segment 28 is inserted into the shaped channel 14 in a similar manner as exemplified in FIG. 4B. In this embodiment, the cross-sectional area of the mouth of the tray member defined by the first tray member rim 16 is less restricted as compared with the embodiment of the invention depicted in FIG. 1.

Turning to FIGS. 8 & 9, therein are illustrations of a preferred embodiment of the invention wherein the smaller second tray member 2 and first tray member 4 are secured to each other using screw thread connections to achieve a “ready-for-sale” condition.

FIG. 9 shows the second smaller tray member 2 inverted and attached to the first tray member 4 to form an integrated food container system 21, and as illustrated, the male helical thread 40 in the second smaller tray member 2 is formed on the tapered surface 41, and designed to engage a similarly configured but complementary helical female thread 38 formed on the inner wall 13. When engaged in this manner, the faying surfaces 34, 36 of the tray members 2, 4 respectively, in concert with the threaded connections, makes leak-resistant the container system. Turning to FIG. 10, therein is illustrated an isometric view of the second smaller tray member 2 of the embodiment in FIGS. 8 & 9. As shown, a discrete male rib thread 42 is formed on the outer sidewall 12, and that is used to secure the inverted second smaller tray member 2 to the first tray member rim 16. The manner of engagement of the inverted second smaller tray member 2 is further exemplified in FIG. 11 which is a cross-sectional view of the container system 1 in FIG. 10 taken along the line N-N. Attaching the inverted second smaller tray member 2 to the first tray member 4 is achieved by placing the first tray member rim 16 into the shaped channel 14 and then sliding said shaped channel 14 along the tray rim so that the discrete male rib thread 42 slides along the female groove thread 38 of the first tray member 4; and the opposing resistance caused by the force between the inner sidewall 10 and the first tray member rim 16 results in an interference fit that firmly holds the inverted second smaller tray member 2 and first tray member 4 together.

Turning now to FIGS. 12, 13, 14 & 15, therein is shown renditions of another embodiment of the invention. This embodiment possesses all the features of the embodiment depicted in FIGS. 8, 9, 10 & 11, except that securing the inverted second smaller tray member 2 to the first member 4 is further facilitated by a discrete male protuberance 44. Commonly referred to as a stud snap-fit lock, securing the inverted second smaller tray member 2 to the tray is achieved by sliding the shaped channel 14 along the first tray member rim 16 as previously described and exemplified in FIGS. 8, 9, 10 & 11, and by further ensuring that the discrete male protuberance 44 in the smaller second tray member 2 “snaps” into the complementary female depression 46 of the first tray member 4.

Turning to FIGS. 16, 17, 18 & 19, therein are shown another rigid polymer construct embodiment of a further enhancement of the previously described embodiment of the present invention, the enhancement being the formation of a male protuberance 53 that is formed into the floor of the shaped channel 14 and a complementary female slot 54 formed to accept the male protuberance 53. The coupling of the two tray members is further enhanced by the use of a snap-fit grip mechanical means. In these illustrations, shown formed into the male protuberance 53 is a discrete rib edge 56 that mechanically engages a corresponding complementary ledge 58 in the female slot 54 to help secure the smaller second tray member 2 to the first tray member 4.

Turning to FIG. 20, therein is shown a first container system 50 stacked upon a second container system 52 of the present invention. The dimensions and configuration of the base 48 of the tray member 4 are such that it permits a close fit with cavity 23 formed in the top of the lid member 2. The stacking feature of the container system to facilitate transportation, as well as display at the market.

FIG. 21 shows a different embodiment of the present invention that does not utilize the smaller second tray members to act as a lid that mates with the mouth of the first tray member. As shown, there is illustrated a first tray member 4 to which is attached two smaller tray members 60, 62. The manner of attachment of the smaller tray members 60, 62 to the first tray member 4 have previously been described.

Although particular embodiments of the invention have been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims. 

1. A container system comprising: a first tray member: a second tray member, said second tray member having a bottom surface into which is formed a shaped channel, the shaped channel being defined by a floor, an inner sidewall and an outer sidewall; and wherein the rim of said first tray member may be inserted into said shaped channel so that said second tray member is mechanically held to said first tray member to form an integrated food container system.
 2. A container system comprising: a first tray member: a second tray member, said second tray member having a bottom surface into which is formed a shaped channel, said shaped channel being defined by a floor, an inner sidewall and an outer sidewall; wherein said first tray member and said second tray member possess complementary mating rims that when held together define an enclosure; and wherein said rim of said first tray member may be inserted into said shaped channel so that said second tray member is mechanically held to said first tray member to form an integrated food container system.
 3. The claim as in claim 2 wherein said complementary mating rims of said first tray member and said second tray member are releaseably lockable to each other.
 4. The claim as in claim 3 wherein said first and second tray members are releaseably lockable by a snap-fit lock.
 5. The claim as in claim 3 wherein said first and second tray members are releaseably lockable by a threaded connection.
 6. The claim as in claim 3 wherein said first and second tray members are releaseably lockable by tamper-evident, tamper-resistant features.
 7. The claim as in claim 2 wherein said first tray member has a base that is configured to fit snugly within a cavity formed into said bottom surface of said second tray member.
 8. The claim as in claim 7 wherein the minimum depth of said cavity is 3/16 inch.
 9. The claim as in claim 1 or 2 further including mechanical means for attaching said shaped channel to said first tray member rim comprising an interference fit.
 10. The claim as in claim 1 or 2 further including mechanical means of for attaching said shaped channel to said first tray member rim comprising a snap-fit grip.
 11. The claim as in claim 1 or 2 wherein inner and outer sidewalls are curved, linear or any combination thereof.
 12. The claim as in claim 1 or 2 wherein the minimum depth of said shaped channel as measured from said second tray member bottom surface is 3/16 inches.
 13. The claim as in claim 1 or 2 wherein said second tray member of the integrated food container system is supported by said first tray member.
 14. The claim as in claim 13 wherein said shaped channel is held to said first tray rim via a threaded connection.
 15. The claim as in claim 1 or 2 wherein the planes of the surfaces of the inner and outer sidewalls of the shaped channel coincide at the points beneath the bottom surface of the second tray member to form an acute angle.
 16. The claim as in claim 1 or 2 wherein the material of the first and second tray members is Polystyrene, Polypropylene, Polyethylene Terephthalate, Polylactide, Polyvinyl Chloride, or other rigid polymers.
 17. The claim as in claim 1 or 2 wherein the process for constructing the first and second tray members is taken from the group consisting of thermoforming, injection molding, transfer molding and blow molding.
 18. The claim as in claim 1 or 2 wherein the container system is circular, elliptical, rectangular, square, or other polygonal shape when viewed from above. 